Drywall Repair Device

ABSTRACT

A drywall repair system comprises a handle, a saw, and a plug. The handle has a first and second side. The first side has a knob positioned on a first side and the saw removably engaged to the second side of the base. The saw comprises a plurality of primary blades and secondary blades positioned about a central axis. The secondary blades have a larger circumference than the circumference of the primary blades. The plug has an interior side and an exterior side separated by a bezeled circumference. In use, the user connects the saw and handle components, and rotates the handle to cut a damaged portion of drywall. The plug is inserted into the cut section of drywall and the damaged drywall is repaired

CROSS-REFERENCE TO RELATED APPLICATION(S)

The present application claims priority to U.S. Provisional Patent Application No. 62/273,917 filed on the Dec. 31, 2016, entitled “The Plug” the entire disclosure of which is incorporated by reference herein.

BACKGROUND OF THE INVENTION

1. Field of Invention

The present invention relates to the field of drywall hole repair devices, and a system for the use thereof.

2. Description of Related Art

Drywall, also referred to as plasterboard, wallboard, or gypsum board is a panel made of calcium sulfate dihydrate with or without additives and is normally pressed between a facer and a backer. It is typically used to form interior walls and ceilings, as it is easy to use, and much faster than traditional methods.

While drywall is much easier for carpenters to use, it is prone to punctures following an acute impact, leaving holes in the drywall. Fixing drywall holes is a common occurrence for many homeowners. The process of fixing the damage is something almost every homeowner will encounter at least once in their lifetimes.

Currently, a few popular methods for fixing the damage are used. If the hole is large enough, it may be necessary to replace an entire panel of drywall. This process is as simple as removing the damaged panel, and replacing it with a new one, using drywall screws to anchor the panel to studs in the wall. Smaller holes can be fixed by one of a few common methods. A popular method involves placing self-adhesive mesh over the hole and covering the mesh and hole with a lightweight joint compound. Using a drywall knife, the user must layer the joint compound over the hole, and then sand the compound down until it is smooth.

Medium holes can be fixed by implanting a small piece of drywall and cutting the damaged drywall to fit the implanted piece. This process is straightforward, but requires the user to further damage the wall, creating potential problems if not performed correctly.

The typical homeowner may feel intimidated by something as seemingly daunting as repairing a wall, and as a result they may instead opt to hire a professional for a rather large fee. A suitable solution is desired.

Based on the foregoing, there is a need in the art for a quick and simple drywall repair system that is accessible to homeowners of any skill level while maintaining the integrity of the drywall.

SUMMARY OF THE INVENTION

A drywall repair device has a handle, having a knob and a base portion. The knob is positioned on a first side of the base and a second side is on the opposing side of the base. The handle removably engages from a saw at the second side of the base.

The saw comprises a central axis with a plurality of primary blades positioned around the central axis. A plurality of secondary blades are also positioned around the central axis. Each of the plurality of secondary blades are each a triangular prism. In an embodiment, each of the plurality of secondary blades are positioned equidistant about the central axis. A plug has an interior side, an exterior side, and a bezel portion.

In an embodiment, the base has one or more through-holes. Each through-hole is adapted to receive a screw, wherein each screw removably attaches the saw at the base.

In an embodiment, the second side of the base further comprises a trough. The trough is defined by a ridge positioned about the perimeter of the second side of the base.

In an embodiment, the knob protrudes perpendicular from the base and positioned on an opposing side of the knob.

A drywall repair device method comprises the steps of removably attaching a saw to a handle. Next, the user grasps the handle and positions the saw over a damaged section of drywall. The handle is rotated with the saw attached, cutting the damaged section of drywall until the ridge is reached. The plug is then inserted into the drywall and sanded as necessary. The user may elect to cover the plug with a joint compound, sand, paint, or in other ways cover the plug to match the surrounding drywall.

The foregoing, and other features and advantages of the invention, will be apparent from the following, more particular description of the preferred embodiments of the invention, the accompanying drawings, and the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the present invention, the objects and advantages thereof, reference is now made to the ensuing descriptions taken in connection with the accompanying drawings briefly described as follows.

FIG. 1 is a perspective view of the plug, handle, saw components, according to an embodiment of the present invention;

FIG. 2A is a front elevation view of the saw and handle components, according to an embodiment of the present invention;

FIG. 2B is a perspective view of the saw and handle components, according to an embodiment of the present invention;

FIG. 3A is a perspective view of the handle and saw components, according to an embodiment of the present invention;

FIG. 3B is a front elevation view view of the handle and saw components, according to an embodiment of the present invention;

FIG. 4A is a perspective view of the saw and damaged section of drywall, according to an embodiment of the present invention;

FIG. 4B is a perspective view of the repaired drywall, according to an embodiment of the present invention;

FIG. 4C is a perspective view of the plug and repaired drywall, according to an embodiment of the present invention;

FIG. 4D is a perspective view of the plug inserted into the repaired drywall, according to an embodiment of the present invention;

FIG. 4E is a perspective view of the user sanding the repaired drywall, according to an embodiment of the present invention; and

FIG. 5 is a flowchart of the method of use, according to an embodiment of the present invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Preferred embodiments of the present invention and their advantages may be understood by referring to FIGS. 1-5, wherein like reference numerals refer to like elements.

In general, the present invention refers to both a saw and a plug. Both components of the system are used in series in order to quickly, safely, and simply repair a hole in a section of drywall.

In reference to FIG. 1, the disassociated plug 10, handle 20, and saw 30 components are shown. In an embodiment, the plug 10 comprises an interior side 11 and exterior side 12 that opposes the first. The exterior side 12 opposes the interior side and is identified by its larger diameter than the interior side 11. A bezel portion 13 tapers from the larger diameter of the exterior side 12 to the smaller diameter of the interior side 11. An axis 14 is in the center of the interior side 11 of the plug.

In further reference to FIG. 1, the saw 30 component is shown disassociated from the handle 20 component. The saw 30 comprises a central axis 31 with a plurality of blades 32 positioned radially about the central axis 31. A generally vertical interior wall 33 extends upwards through the perimeter of the central axis 31. The central axis functions to keep the device light by removing inner material. Each of the plurality of blades 32 extend downwards at an acute angle in reference to the interior wall 33. A sidewall 34 protrudes vertically from a bottom end 35 of the blades 32 and extends to a set of radially spaced secondary blades 36. The blades 32 are configured to cut a generally conical shape into a section of damaged drywall, providing a clean cut after the blades have been rotated. The secondary blades 36 are configured to form a bezel in the damaged drywall, matching the bezel portion 13 of the plug. In a preferred embodiment, each of the secondary blades 36 form a right triangle in reference to the base. For example, a right angle is made between the saw and the base, and each of the secondary blades form a triangular prism. A handle 20 is adapted to releasably engage the saw 30 component. The handle 20 comprises a base 21 and a knob 22 dissecting the base at a cross-section. The base has a first side 27 and a second side 28. The knob 22 is positioned on the first side 27 and the saw is removably attached to the second 28. The base has at least two through-holes 23. To connect the saw 30 to the handle 20, screws are positioned through the through-holes 23 to engage the saw 30, holding it in place during use. The knob extends perpendicular to the base 21 and allows for increased torsion when in use. The saw contacts a second side of the base 21, positioned at the opposite side of the knob 22.

In reference to FIG. 2A and FIG. 2B, the saw 30 component and handle 20 component are shown engaged with one another once screws have been positioned through the through-hole of the base 21. The second side 24 of the handle comprises a trough 25 positioned central to the perimeter of the base 21. The trough allows for loose materials to collect when the saw 30 is cutting away material from the damaged drywall. In a preferred embodiment, eight blades are positioned radially, and equidistant from one another, about the circumference of the saw 30. The base 21 has a larger circumference than the saw 30 to form a stopper once the user has effectively cut the drywall to receive the plug. A ridge 26 embodies the stopping portion of the handle, contacting the drywall and halting the further penetration of the saw 30.

In reference to FIG. 3A and FIG. 3B, the handle 20 component is shown. As mentioned, the base 21 has at least two through-holes adapted to receive a screw, allowing for the engagement of the saw 30 component. The knob 22 protrudes generally perpendicular to the base 21 allowing for the user to hold and rotate the handle 20 and saw 30 to effectively cut the damaged portion of drywall. In a preferred embodiment, the handle 20 at its widest point protrudes farther than the diameter of the base 21 permitting increased torsion.

In an alternate embodiment, the saw 30 and handle 20 are integrally molded or glued together. Other means of attachment known in the art may be used, so long as the attachment of the two components is strong enough to remain engaged after repeated rotational forces are applied in any direction.

In reference to FIG. 4A, a section of drywall 40 has been damaged and is in need of repair. In use, the user will position the handle 20 with the engaged saw 30 at the location of the damaged section 41. The saw 30 contacts the damaged section 41 while the user grips the knob 22, preferentially with their thumb and index finger. The user then rotates the handle 20, rotating the saw 30 and cutting the underlying damaged drywall to form a smooth and uniform cut in the drywall.

FIG. 4B shows the smooth and uniform cut in the drywall 40. The drywall 40 has a perpendicular wall 43 in reference to the face of the drywall. The secondary blades 36 cut a drywall bezel 45 to compliment the bezel 13 portion of the plug 10. In reference to FIGS. 4C and 4D, the user has inserted the plug into the drywall 40. The plug should fit into the damaged section that has been cut by the saw 30. The exterior portion of the plug is flush with the face 44 of the drywall 40 providing a smooth surface.

In reference to FIGS. 4D and 4E, the user may optionally sand the plug to allow the exterior 12 to be flush with the face of the drywall 40. Structural integrity of the drywall is maintained. The user may select to use a joint compound or other material known in the art. Further, the plug 10 allows the user to paint, texturize, or modify the surface to match the surrounding drywall, effectively rendering the damage obsolete. An adhesive is used to affix the plug to the wall. In a preferred embodiment, silicone is used.

The handle 20 is preferentially made of one of a plurality of plastics or polymers known in the art. The plastic should be strong enough to withstand the rotational forces applied by the user when cutting the hole in the wall. The saw 30 is made of one of a plurality of metals known in the art. The saw must be made of a dense resilient material so that the blades 32,36 retain their sharpness over repeated uses. In an alternate embodiment, the handle 20 and saw 30 components are integrally molded to one another, and made of the same material such as metal, or a resilient polymer.

FIG. 5 is a flowchart, describing a method of use of the present invention. In step 10 the user affixes the saw to the handle, if it is not already attached. Affixing the two components can be accomplished by inserting screws through the through-holes of the base of the handle component, or by other means known in the art such as glue. In alternate embodiments, the two components are integrally molded to one another, forgoing the need for affixation. In step 15, the user grasps the handle, preferentially with their thumb and index fingers. In step 20, the user positions the saw over and into the damaged section of the drywall. In step 25, the user rotates the handle, turning the handle and saw component to cut the damaged section of drywall into a smooth and uniform surface that compliments the surfaces of the plug. In step 30, the user cuts the drywall until the ridge on the base of the handle contacts the face of the drywall. In step 35, the user inserts the plug into the cut section of drywall, until the exterior surface of the plug is flush with the face of the drywall. In step 40, the user sands the exterior surface of the plug if necessary.

In an embodiment, the user may elect to cover the plug with a joint compound that can be sanded and painted to match the texture, color, and tone of the wall.

The invention has been described herein using specific embodiments for the purposes of illustration only. It will be readily apparent to one of ordinary skill in the art, however, that the principles of the invention can be embodied in other ways. Therefore, the invention should not be regarded as being limited in scope to the specific embodiments disclosed herein, but instead as being fully commensurate in scope with the following claims. 

I claim:
 1. A drywall repair device comprising: a. a handle having a base, the base further comprises a first side and a second side, the first side having a knob protruding perpendicular to the base; b. a saw removably attached to the second side of the base, the saw comprising: i. a plurality of primary blades positioned about a central axis; ii. a plurality of secondary blades positioned about the central axis, wherein the plurality of secondary blades form a circumference larger than a circumference of the plurality of primary blades; and c. a plug, having an interior side and an exterior side separated by a bezeled circumference equal to the circumference of the plurality of secondary blades portion.
 2. The device of claim 1, wherein the second side is defined by a ridged perimeter, wherein the ridged perimeter halts cutting of the drywall.
 3. The device of claim 1, wherein each of the plurality of secondary blades are a triangular prism.
 4. The device of claim 6, wherein the plurality of secondary blades are positioned equidistant from one another.
 5. The device of claim 1, wherein the saw further comprises a central axis.
 6. A drywall repair device method comprising the steps of: a. removably attaching a saw to a handle; b. grasping the handle; c. positioning the saw over a damaged section of drywall; d. rotating the handle with the saw attached; e. cutting the damaged section of drywall; f. inserting a plug into the drywall; and g. sanding an exterior surface of the plug.
 7. The method of claim 6, wherein cutting the damaged section of drywall further comprises the step of cutting the section of drywall until the ridged perimeter of the second side of the base is reached.
 8. The method of claim 6, wherein inserting the plug into the drywall further comprises the step of disposing an adhesive onto a bezel portion of the plug.
 9. The method of claim 6, wherein sanding the exterior surface of the plug further comprises the step of covering the exterior surface of the plug with a joint compound. 